ADP1043A Evaluation Board
Forward Active Clamp
PRD 1168
Reference Design
FEATURES
Forward Active Clamp with Synchronous rectifier
Voltage Feedback Loop
Dimensions: 58.4mm×61mm×12mm (Half Brick)
Input Voltage Range: -34V to -60V DC
Output Voltage/Current: 18V/6A DC
95% Max. Efficiency
I2C serial interface
Software GUI
PRD 1168 OVERVIEW
The PRD 1168 is designed for evaluating ADP1043A application using forward active clamp topology. The ADP1043A is a secondary
side power supply controller IC designed to provide all the functions that are typically needed in an AC-DC or isolated DC-DC
application.
The board output 18V/6A DC from a -34to -60VDC input. The maximum efficiency can reach 95%. It has versatile protection, such as
OCP, SCP, OTP etc. And the protection mode also can be programmed through GUI.
Using this board and its accompanying software, the ADP1043A can be interfaced to any PC running Windows 2000, Windows NT,
Windows XP or Windows Vista via the computer's USB port.
EVALUATION EQUIPMENT
To evaluate this demo board, a PC, oscilloscope, electronic load and a DC power source are required.
SR2
Figure 1 Forward Active Clamp Topology.
Rev. Prelim.A, Oct. 2009
10/30/2009 4:36:00 PM
Information furnished by Analog Devices is believed to be accurate and reliable.
However, no responsibility is assumed by Analog Devices for its use, nor for any
infringements of patents or other rights of third parties that may result from its use.
Specifications subject to change without notice. No license is granted by
implication or otherwise under any patent or patent rights of Analog Devices.
Trademarks and registered trademarks are the property of their respective owners.
One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106 U.S.A.
Tel: 781.329.4700
www.analog.com
Fax: 781.326.8703 © 2009 Analog Devices, Inc. All rights reserved.
Reference Design
PRD 1168
TABLE OF CONTENTS
Features ......................................................................................................................................................................................................... 1 PRD 1168 Overview ..................................................................................................................................................................................... 1 Evaluation Equipment ................................................................................................................................................................................... 1 Evaluation Board Hardware .......................................................................................................................................................................... 4 Specifications ............................................................................................................................................................................................ 4 Topology and operation waveforms .......................................................................................................................................................... 4 Connectors................................................................................................................................................................................................. 5 Interface Connector ................................................................................................................................................................................... 5 Test Results ................................................................................................................................................................................................... 7 Getting Started............................................................................................................................................................................................... 9 Equipment ................................................................................................................................................................................................. 9 Setup.......................................................................................................................................................................................................... 9 Board Evaluation ......................................................................................................................................................................................... 11 Line and Load Voltage Regulation .......................................................................................................................................................... 11 Output Voltage Setting ............................................................................................................................................................................ 11 Soft Start.................................................................................................................................................................................................. 11 Digital Filter – Transient Analysis ........................................................................................................................................................... 12 PWM – Switching Frequency ................................................................................................................................................................. 13 Light Load Optimization ......................................................................................................................................................................... 13 Primary Side Current Sense and Secondary Side Current Sense ............................................................................................................. 13 Flags and Fault configurations ................................................................................................................................................................ 14 Flag and Fault Response Configuration: ............................................................................................................................................. 14 Appendix ..................................................................................................................................................................................................... 16 Schematic ................................................................................................................................................................................................ 16 Bill of Materials ...................................................................................................................................................................................... 18 PCB Layout ............................................................................................................................................................................................. 20 Board Setting ........................................................................................................................................................................................... 22 Register Setting ....................................................................................................................................................................................... 23 NOTES ........................................................................................................................................................................................................ 27 Rev Prelim A Oct.2009 | Page 2 of 27
Reference Design
PRD 1168
TABLE OF FIGURES
Figure 1 Forward Active Clamp Topology. ................................................................................................................................................... 1 Figure 2 Driver Signal ................................................................................................................................................................................. 4 Figure 3 Pin Connection Diagram (Bottom view) ....................................................................................................................................... 5 Figure 4 Eval Board Picture(Bottom View) ................................................................................................................................................. 6 Figure 5 Test Configuration for the Evaluation Board ................................................................................................................................. 6 Figure 6 Efficiency....................................................................................................................................................................................... 7 Figure 7 Output Voltage Response................................................................................................................................................................ 7 Figure 8 Output Voltage Ripple at No Load Current. ................................................................................................................................... 7 Figure 9 Output Voltage Ripple at Nominal Load Current. .......................................................................................................................... 7 Figure 10 Turn-on Transient at No Load Current. ........................................................................................................................................ 8 Figure 11 Turn-on Transient at Nominal Load Current................................................................................................................................. 8 Figure 12 Output Over Current. .................................................................................................................................................................... 8 Figure 13 Output Short Circuit. .................................................................................................................................................................... 8 Figure 14 Connection with Computer .......................................................................................................................................................... 9 Figure 15 Getting Started ............................................................................................................................................................................. 9 Figure 16 Load Board Setting .................................................................................................................................................................... 10 Figure 17 Graphical User Interface.............................................................................................................................................................11 Figure 18 General Settings Window .......................................................................................................................................................... 12 Figure 19 Digital Filter Window ................................................................................................................................................................ 12 Figure 20 Timing Window ......................................................................................................................................................................... 13 Figure 21 Light Load Current Threshold ................................................................................................................................................... 13 Figure 22 Flags .......................................................................................................................................................................................... 14 Figure 23 Fault Configurations .................................................................................................................................................................. 15
Figure 24 Main Circuit .............................................................................................................................................................................. 16 Figure 25 ADP1043A Control Circuit ....................................................................................................................................................... 17 Figure 26 Aux. Power Circuit .................................................................................................................................................................... 17 Figure 27 Top View of Board..................................................................................................................................................................... 20
Figure 28 Bottom View of Board ............................................................................................................................................................... 21 Rev Prelim A Oct.2009 | Page 3 of 27
Reference Design
PRD 1168
EVALUATION BOARD HARDWARE
SPECIFICATIONS
•
Nominal input voltage: -48 DC
•
Input voltage range: -34~-60V DC
•
Nominal output voltage: 18V DC
•
Nominal output current: 6A DC
•
Switching frequency: 180kHz
•
Efficiency: 95% at full load
TOPOLOGY AND OPERATION WAVEFORMS
A typical DC/DC switching power supply is the basis for the eval board. It is a forward active clamp with synchronous rectifier topology,
shown as Figure 1. The forward active clamp converter is an isolated converter, which operates with variable duty cycle which can be
over 50%, so that a wide range input converter can provide high efficiency under the conditions of regulated output.
The primary side consists of the input terminals, main switch, aux switch (PMOS) and main transformer. The gate driver signal for the
switches comes from the ADP1043A, through the iCoupler and the drivers. There is also a current transformer (CT), to transmit the
primary side current information to the ADP1043A on the secondary side.
Figure 2 Driver Signal
Q1
D
t
Q2
t
SR1
t
SR2
1-D
t
Ts
The secondary side power stage consists of the synchronous rectifiers, inductor, output capacitor and sensing resistor. This provides 18V
@ 6A at the output. The ADP1043A is located on the secondary side. The ADP1043A provides the feedback signal that is used to
regulate the voltage, limit the current, allow current sharing and shutdown to be implemented. Low side current sensing is used.
There is a 8pins connector on the board. 4pins of the connector is for I2C. This allows the PC software to communicate with the eval
board through the USB port of the PC. The user can readily change register settings on the ADP1043A this way, and also monitor the
status registers.
The eval board is designed with a 2mOhm RSENSE resistor. The power supply is designed to support a maximum continuous output of
6 A.
A variable load is required to perform a thorough evaluation. The output voltage is available between P4 and P5. This is also where the
load should be connected.
The power supply will be in Continuous Conduction Mode. If the synchronous rectifiers are enabled, the power supply will remain in
CCM mode over the full load range.
Rev Prelim A Oct.2009 | Page 4 of 27
Reference Design
PRD 1168
Figure 3 Pin Connection Diagram (Bottom View)
CONNECTORS
The connections to the eval board are shown in Table 1.
Table 1. Power module pin assignment
Pin
Designation
Eval Board Function
P1
Vin-
Negative Input
P2
On/Off
Remote Control
P3
Vin+
Positive Input
P4
Vo-
Negative Output
P5
Vo+
Positive Output
P6
Interface
Interface
INTERFACE CONNECTOR
The signal pins are P6.1~P6.8 as shown in Table 2. Among them P6.7, P6.5, P6.3 and P6.1 are connected to USB dongle.
Table 2. Signal pins
Pin
Designation
Pin
Designation
P6.1
GND
P6.5
SCL
P6.2
PGOOD
P6.6
Vsen-
P6.3
SDA
P6.7
5V
P6.4
Vsen+
P6.8
Address
Rev Prelim A Oct.2009 | Page 5 of 27
Reference Design
PRD 1168
Figure 3 shows the photo of eval board. Figure 4 provides a typical circuit diagram which details the filtering for normal operation and
output ripple test
Figure 4 Eval Board Picture(Bottom View)
Figure 5 Test Configuration for the Evaluation Board
Rev Prelim A Oct.2009 | Page 6 of 27
Reference Design
PRD 1168
TEST RESULTS
Figure 6 Efficiency at nominal output voltage vs. load current for
minimum, nominal, and maximum input voltage at 25°C.
Figure 7 Output voltage response to step-change in load current (25%75%-25% of Iout(max): dI/dt = 1A/μs). Ch 2: Vout (500mV/div), Ch 4:
Iout (2A/div).
Figure 8 Output voltage ripple at nominal input voltage and no load
current . Ch 2: Vout (50mV/div), Bandwidth: 20 MHz.
Figure 9 Output voltage ripple at nominal input voltage and nominal
load current. Ch 2: Vout (50mV/div), Bandwidth: 20 MHz.
Rev Prelim A Oct.2009 | Page 7 of 27
Reference Design
PRD 1168
Figure 10 Turn-on transient at nominal input voltage and no load
current. Ch 2: Vout (5V/div), Ch 4: Load Current (5A/div).
Figure 11 Turn-on transient at nominal input voltage and nominal load
current. Ch 2: Vout (5V/div), Ch 4: Load Current (5A/div).
Figure 12 Output over current protection function. Increase load
current at nominal input voltage to over current limit. Ch 2: Vout
(5V/div), Ch 4: Load Current (5A/div).
Figure 13 Output short circuit protection function. Turn on at nominal
input voltage and rated load current then short circuit. Ch 2: Vout
(5V/div), Ch 4: Load Current (5A/div).
Rev Prelim A Oct.2009 | Page 8 of 27
Reference Design
PRD 1168
GETTING STARTED
EQUIPMENT
•
•
•
•
•
•
DC Power Supply 0-60V (Sorensen DLM150-20E)
Electronic Load capable of 18V/6A (Chroma 63112)
Oscilloscope (Tektronix TDS5054B)
PC with ADP1043A GUI installed
Precision Digital Multi-meters (Agilent 34401A)
Current Probe for measuring up to 6A DC (Tektronix TCP202)
SETUP
NOTE: DO NOT CONNECT THE USB CABLE TO THE EVAL BOARD UNTIL AFTER THE SOFTWARE HAS BEEN
INSTALLED.
Figure 14 Connection with Computer
1.
Install the ADP1043A software. Refer to the Quick Start Guide that comes on the CD (If already installed, skip to the next
step).
2.
Connect the evaluation board to the USB port on the computer, using the “USB to I2C interface” dongle. If the dongle driver
was not previously installed, run the software from the Start Menu under “Programs/ADI/ADP1043A”.
3.
The software should report that the ADP1043A has been located on the board. Click Finish to proceed to the Main Software
Interface Window.
Figure 15 Getting Started
4.
Click on the
icon and “Load Board Setting”: select the “PRD1168.43b file”. This file contains all the board information
including values of shunt and voltage dividers
Rev Prelim A Oct.2009 | Page 9 of 27
Reference Design
PRD 1168
Figure 16 Load Board Setting
5.
The ADP1043A is pre-programmed and calibrated, so there is no programming necessary.
6.
Connect an electronic load at the output.
7.
For the input voltage source, a DC power supply can be used. The input voltage range is -34V to -60 VDC (-48VDC is
recommended). This input voltage is the signal which will be regulated to provide a 18V/6A supply at the output. Set the
voltage to -48VDC.
8.
The eval board should now up and running, and ready to evaluate. The output should be 18 VDC.
Rev Prelim A Oct.2009 | Page 10 of 27
Reference Design
PRD 1168
BOARD EVALUATION
The ADP1043A is optimized for improving the power supply design and evaluation process. The goal of this eval kit is to allow the user
to get an insight into the flexibility offered by the extensive programming options offered by the ADP1043A.
The ADP1043A performs many monitoring and housekeeping functions in the power supply. The eval board allows the user to simulate
various events that could affect the ADP1043A in a working system. The user can monitor how the ADP1043A handles this event in
many ways. One way is to use an oscilloscope and/or multi-meter, and probe the eval board, to see various conditions in the system. The
user can also use the software to monitor the conditions of the ADP1043A, and how it has reacted to the event. The following section
gives some experiments that the user might typically evaluate.
LINE AND LOAD VOLTAGE REGULATION
Vary the input voltage from -34VDC to -60VDC. The output voltage remains18V. Vary the load current from 0 to 6A. The output voltage
remains 18V. The line and load regulation are less than ±1%.
Figure 17 Graphical User Interface
OUTPUT VOLTAGE SETTING
The output voltage setting is programmable. Using the Voltage Setting window in the software, adjust the output voltage (using the o/p
trim menu). Monitor the actual output voltage of the power supply using the software or a multi-meter, or looking at the output voltage
reading on the electronic load. It should match the programmed value. This will be used to calibrate the power supply in the production
environment. By doing this evaluation, the user can see how the ADP1043A can be trimmed digitally to adjust the output voltage.
SOFT START
Once the input voltage is applied it is possible to test the Soft Start of the ADP1043A. The settings are located in the General Settings
Window. Please refer to the Software Reference Guide for a detailed explanation of all the controls (EVAL-ADP1043A-GUI-RG).
Rev Prelim A Oct.2009 | Page 11 of 27
Reference Design
PRD 1168
Figure 18 General Settings Window
Soft Start is enabled and set to 20ms. You can experiment with different times.
DIGITAL FILTER – TRANSIENT ANALYSIS
The digital filter can be changed using the software. The effect on transient analysis can be evaluated this way. Connect a switching
electronic load to the output of the eval board. The load should be set to switch between 25%-75%, changing every 10msecs. Set up an
oscilloscope to capture the transient waveform of the power supply output.
Use a differential probe on the scope, connecting it to the eval board output. Turn on the load, and note the waveform response.
Now, vary the digital filter using the software. Click on “Filter Settings” the window shows the filter settings for Normal mode. Click on
the curve to move position of poles, zeroes and gains.
Figure 19 Digital Filter Window
The transient response will change. This evaluation shows the user how the digital filter can easily be programmed to optimize the
transient response of the power supply.
Rev Prelim A Oct.2009 | Page 12 of 27
Reference Design
PRD 1168
PWM – SWITCHING FREQUENCY
The converter switching frequency is programmable. In the “PWM & SR Settings” change the switching frequency.
The minimum and maximum modulation limits can also be modified.
Figure 20 Timing Window
NOTE: It is recommended to evaluate this feature with the power supply turned off. This prevents the chance of damaging the power
supply by introducing shoot-through.
LIGHT LOAD OPTIMIZATION
The ADP1043A can be programmed to optimize performance when a output current drops below a certain level.
The threshold for light load mode can be programmed in the digital filter window.
Once the current will drop below this level the sync rectifiers (SR1 and SR2) will be disabled. The “Light Load Mode Settings” will be
used. The response time for the ADP1043A to switch from one mode to another is between 10 and 20ms.
The light load mode can be disabled by selecting a Light Load Current Threshold of 0%.
Figure 21 Light Load Current Threshold
PRIMARY SIDE CURRENT SENSE AND SECONDARY SIDE CURRENT SENSE
Current sensing is available for both the primary side current and the secondary side current. Primary side current sensing is performed
using the current transformer, T1. Secondary side current sensing uses a low-side sense resistor.
Open the Monitor window in the software. Click on the Flags and Readings tab. Adjust the load current from 0A to 6A. The input current
and output current values will change in the software, matching the changes being made at the load.
Rev Prelim A Oct.2009 | Page 13 of 27
Reference Design
PRD 1168
FLAGS AND FAULT CONFIGURATIONS
Open the Monitor window in the software. Click on the Flags and Readings tab. The window will show all of the fault flags. If a flag is
set, then there is a red box next to the flag. If the flag is ok, then there is a green box next to the flag.
Set the load current to 0.3A. The CS2 OCP flag should be green.
Figure 22 Flags
Now change the load to 8A. The CS2 OCP flag should now have turned red, because the CS2 OCP threshold has been reached. The
board wills ender in hiccup mode and try and restart.
Set the load back to 2A, and the flag turns green again. This shows how the user can easily monitor the health of the power supply by
monitoring the status of the various flags.
Flag and Fault Response Configuration:
The ADP1043A is programmed to respond to the various fault conditions in the Fault Configuration Tab.
Rev Prelim A Oct.2009 | Page 14 of 27
Reference Design
PRD 1168
Figure 23 Fault Configurations
You can change the resolve issue to “Remain Disabled”. If the over current is applied again the ADP1043A will shut down and remain
off until PSON is cycled.
This evaluation shows how it is quite easy to configure the response to a fault condition. Change the load back to 2A, then toggle the
PS_ON switch to restart the power supply.
Rev Prelim A Oct.2009 | Page 15 of 27
Reference Design
PRD 1168
APPENDIX
SCHEMATIC
3 CS+
Vin+
Vout+
3
JP1
4
1
C7
68nF
C15
2.2uF
2.2uF
2.2uF
32uH
R92 C47
C46 10nF
5.1k 10nF
2
MURA110
R91
5.1k
R90
5.1k
C9
C10
C11
C12
C13
10uF
4.7uF
10uF
10uF
4.7uF
R11
10K
PGND
Vout-
1
Q2
Si3437
Q3
IPD053N08N3
R89
Q7
Vin+
R10
R7
10K
8
7
6
5
12V_SEC
C22
1uF
ADP3634
EN
INA
GND
INB
ADP3634
EN
INA
GND
INB
PAD
OTW
OUTA
VS
OUTB
1
2
3
4
5V_PRI
U3
8
7
C19 6
5
0.1uF
5V_PRI
10K
R99
5.1K
Q9
D13
ZR431F01
R62
ON/OFF
1
MMBT2907AW1
R72
1K
C20
0.1uF
R101
0
220
D12
BAV70WT1
C38
10nF
C40
1uF
R100
5.1K
OUTA
OUTB
OUTB
SR1
1
2
3
4
VDD2VDD1
VOA
VIA
VOB
VIB
GND2GND1
VDD1VDD2
VIA
VOA
VIB
VOB
GND1GND2
SR2
12V_SEC
5V_PRI
OUTA
OUTB
5V_PRI
12V_PRI
C21
0.1uF
Vout+
Vout-
0
Vout+
VoutPGND
12V_PRI
PSON
PSON
TR4
TR4
3V3_SEC
3V3_SEC
3V3_SEC
U4
1
2
3
4
8
7
6
5
R102
12V_SEC
0.1uF
220
C48
10nF
1
2
3
EN_LDO4
R104
5.1K
R106 10K
ADUM3210
0
U14
3V3_SEC
PSON
C36
0
1
JP4
AGND
OUTA
12V_SEC
3V3_SEC
5V_PRI
R68
R65
8.2K
SR1
SR1
PGND
R66
330K
SR2
SR2
1
2
3
4
ADUM3210
R69
100K
CS+
AGND
U8
9
C18
1uF
OTW
OUTA
VS
OUTB
Vin-
CS+
U9
R15
2
JP3
8
7
6
5
Vin+
10K
Vin-
12V_PRI
1
JP5
D7
D5
R5
4.7
2m
Vout-
PAD
Vin-
1
1
M7
9
Vin-
C33 0.1uF
1N5819HW
2
1
1N5819HW
1
2
MMBT4403
IPD200N15N3
R6
10K
1
JP11
R16 2
R93
5.1k
D2
C6
1
Q4
PA1005.100NL
BEQ-25
C5
L5
2
2
D3
MURA110
IPD053N08N3
T1
8
7
Vin+
Vout+
TR4
T4
1
1
1
1
1 AGND
Figure 24 Main Circuit
C54
1uF
C55
1uF
GND
IN
OUT
EN
GND4
GND3
GND2
GND1
8
7
6
5
ADP1720ARMZ-3.3
C69
0.1uF
C39
10nF
0
Rev Prelim A Oct.2009 | Page 16 of 27
Reference Design
PRD 1168
Figure 25 ADP1043A Control Circuit
Vout+
PGND Vout-
TR4
D6
BAV70WT1
R25
R23
10
Vout+
C32
100pF
680
Vsen+
R26
34KF
CS+
R30
R34
25
25
R29
34KF
C25
R31
R28
10K
10K
VS1
R27
4.7K
AGND
C58
R33
1nF
34KF
NC VS3+
R74
R32
2KF
100pF
Vout+
Vout+
Vout-
R35
2KF
Vout-
CS+
0
CS2+
CS2-
SR1
SR2
R36
SR1
C59
SR2
16
1
GATE
VS2
3
VS1
8
PGND
CS2-
CS2+
5
4
10
SR2
SR1
9
6
ACSNS
VsenVS3+
VS3-
7
CS1
VCORE
VS3-
31
OUTA
12
OUTB
13
14
15
VDD
TR4
OUTA
26
C27
0.1uF
OUTB
DGND
ADP1043A
OUTC
AGND
OUTD
TPAD
C24
0.1uF
25
33
R43
R64
10K
24
0
3V3_SEC
SDA
2.2K
JP10
R44
2.2K
18
17
30
12V_SEC
Share
23
R67
Vout-
100
SDA
R41
10K
C28
33pF
R45
2.2K
5V
C29
33pF
0 R70 100
R42
0
PGOOD
SCL
RES
ADD
RTD
R40
2.2K
28
3V3_SEC
ADD 29
PGOOD2
PGOOD1
22
FLAGIN
21
PSON
20
19
PSON
SHAREi
12V_SEC
C26
0.1uF
3V3_SEC
2
OUTAUX
SHAREo
OUTB
3V3_SEC
OUTA
PGND
OUTA
OUTB
27
PSON
TR4
PGND
R38 10
3V3_SEC
11
SR2
PSON
Vout-
32
AGND
SR1
2KF
1nF
U6
CS+
AGND
VS3+
R71
10K
1
3
5
7
2
4
6
8
PGOOD
Vsen+
VsenADD
Connector
0
D4
SCL
49.9K 0.1%
1N4148
C30
33pF
0
0
R17
2
12V_SEC
C31
33pF
0
RT1
100KOhm
PGND1
2
JP9
SHORTPIN
0
0
0
Figure 26 Aux. Power Circuit
T3
Vin+
D15
BAV70WT1 12V_SEC
2
5
R76
20K
R78
499K
R77
C41
20K 470pF/250V
D16
MMBD1504A
12V_PRI
1
3
8
7
6
C43
5V_PRI
10uF/16V
3V3_SEC
4
12V_SEC
R85
499K
BSER9-77
8
7
6
5
VD GND
VCC CT
UV VFB
OV COM
U12
R84
55K
1
2
3
4
C45
390pF
R80
680
C49
R81
680
Vout-
5V_PRI
C50
1nF
C35
0.1uF
R83
10K
R82
5.1K
Vin+
Vin-
R79
20K
10uF/16V
3
NCP1031A
C56
1uF
D18
2
0.1uF
PGND
0
1
C34
AGND
D17
BAV70WT1
D8
GND19
1N4148
12V_PRI
C52
Vout1000pF/2000V
C53
MMBZ5231BLT/5.1V
220pF
R86
36K
AUX. Power
Rev Prelim A Oct.2009 | Page 17 of 27
12V_PRI
5V_PRI
3V3_SEC
12V_SEC
AGND
PGND
Vin+
VinVout-
Reference Design
PRD 1168
BILL OF MATERIALS
Item Reference Description Part Number Manufacture Qty
1 2 3 4 CAP 2.2uF/100V X7R 1210 CAP 68nF/250V X7R 1206 CAP 10uF/25V X7R 1210 CAP 4.7uF/25V X7R 1206 C3225X7R2A225K C3216X7R2E683K C3225X7R1E106K C3216X7R1E475K TDK TDK TDK TDK 3 1 3 2 CAP 1uF/16V X7R 0603 C1608X7R1C105K TDK 6 CAP 0.1uF/16V X7R 0402 C1005X7R1C104K TDK 10 CAP 100pF/50V C0G 0402 CAP 33pF/50V C0G 0402 CAP 100pF/50V X7R 0402 CAP 0.1uF/50V X7R 0603 CAP 10nF/25V X7R 0402 CAP 470pF/250V COG 0603 CAP 10uF/16V X7R 1206 CAP 390pF/50V C0G 0402 CAP 10nF/250V X7R 0805 CAP 1nF/50V X7R 0402 CAP 1000pF/2000V X7R 1808 CAP 220pF/50V X7R 0402 Diode 1A 100V Diode 150mA 75V Diode 1A 40V Diode 200mA 70V Adjustable from Vref=2.5V 1% Diode 200mA 200V Zener 5.1V C1005C0G1H101J C1005C0G1H330J C1005X7R1H101J C1608X7R1H104K C1005X7R1E103K C1608C0G2E471J C3216X7R1C106K C1005C0G1H391J C2012X7R2E103K C1005X7R1H102K C4520X7R3D102K C1005X7R1H221K MURA110 1N4148 1N5819HW BAV70WT1 ZR431F01 MMBD1504A MMBZ5231BLT TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK On Semi Fairchild Fairchild Fairchild Zetex Fairchild On Semi 1 4 1 1 3 1 2 1 2 3 1 1 2 2 2 4 1 1 1 Any 1 Jinchuan Vishay Infineon Infineon Infineon On Semi On Semi Vishay Generic 1 1 1 1 1 1 1 1 1 Generic 7 Generic 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 C5,C6,C15 C7 C9,C11,C12 C10,C13 C18,C22,C40,C54 C55,C56 C19,C20,C21,C24,C26,
C27,C34,C35,C36,C69 C25 C28,C29,C30,C31 C32 C33 C38,C39,C48 C41 C43,C49 C45 C46,C47 C50,C58,C59 C52 C53 D2,D3 D4,D8 D5,D7 D6,D12,D15,D17 D13 D16 D18 JP1,JP3,JP4,JP5 JP9,JP10,JP11 L5 M7 Q2 Q3 Q4 Q7 Q9 RT1 R5 R6,R7,R10,R11 R68,R83,R106 R15,R16 Terminal LDC‐25‐7 Aux Switch(PMOS) MOSFET MOSFET MOSFET PNP ‐600mA ‐40V PNP ‐800mA ‐40V THERMISTOR 100KOHM 1% 0603 RES 4.7OHM 5% 1/10W 0603 RES 10KOHM 5% 1/16W 0402 INDUCTOR Si3437 IPD200N15N3 IPD053N08N3 IPD068N10N3 MMBT4403 MMBT2907AWT1 RES 2OHM 5% 1/10W 0603 Rev Prelim A Oct.2009 | Page 18 of 27
Reference Design
PRD 1168
38 39 40 41 42 R17 R23,R38 R25 R26,R29,R33 R27 RES 2OHM 5% 1/16W 0402 RES 10OHM 5% 1/16W 0402 RES 680OHM 5% 1/16W 0402 RES 34KOHM 1% 1/16W 0402 RES4.7KOHM 5% 1/10W 0603 Generic Generic Generic Generic Generic 1 2 1 3 1 43 R28,R31,R41,R64,R71 RES 10KOHM 1% 1/16W 0402 Generic 5 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 R30,R34 R32,R35,R36 R40,R43,R44,R45 R42 R62,R102 R65 R66 R67,R70 R69 R72 R74 R76,R77 R78,R85 R79 R80,R81 R82,R99,R100,R104 R84 R86 R89 R90,R91,R92,R93 R101 T1 T3 T4 U3,U4 U6 U8,U9 U12 RES 25OHM 5% 1/10W 0603 RES 2KOHM 1% 1/16W 0402 RES 2.2KOHM 1% 1/16W 0402 RES 49.9KOHM 0.1% 1/16W 0402 RES 220OHM 5% 1/16W 0402 RES 8.2KOHM 1% 1/16W 0402 RES 330KOHM 1% 1/16W 0402 RES 100OHM 5% 1/16W 0402 RES 100KOHM 5% 1/10W 0603 RES 1KOHM 5% 1/16W 0402 RES 0OHM 5% 1/16W 0402 RES 20KOHM 5% 1/10W 0603 RES 499KFOHM 5% 1/10W 0603 RES 20KOHM 5% 1/16W 0402 RES 680OHM 5% 1/8W 0805 RES 5.1KOHM 5% 1/16W 0402 RES 55KOHM 5% 1/16W 0402 RES 36KOHM 5% 1/16W 0402 RES 2m OHM 1% 1/4W 1206 RES 5.1KOHM 1/4W 1206 RES 0OHM 5% 1/16W 0402 PA1005.100NL 20A 1:100 AUX TRANSFORMER MAIN TRANSFORMER iCoupler Secondary PWM Controller Dual channel driver IC NCP1031A Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Generic Vishay Generic Generic Pulse Jinchuan Jinchuan ADI ADI ADI On Semi 2 3 4 1 2 1 1 2 1 1 1 2 2 1 2 4 1 1 1 4 1 1 1 1 2 1 2 1 72 U14 LDO ADI 1 BSER9‐77 BEQ‐25 ADuM3210 ADP1043A ADP3634 NCP1031A ADP1720ARMZ‐
3.3‐R7 Rev Prelim A Oct.2009 | Page 19 of 27
Reference Design
PRD 1168
PCB Layout
Figure 27 Top view of Board
Rev Prelim A Oct.2009 | Page 20 of 27
Reference Design
PRD 1168
Figure 28 Bottom View of Board
Rev Prelim A Oct.2009 | Page 21 of 27
Reference Design
PRD 1168
BOARD SETTING
Input Voltage = 48 V
N1 = 5
N2 = 4
R (CS2) = 2.07 mOhm
I (load) = 6 A
R1 = 34 KOhm
R2 = 2 KOhm
C3 = 0.001 uF
C4 = 0.001 uF
N1 (CS1) = 1
N2 (CS1) = 100
R (CS1) = 10 Ohm
ESR (L1) = 5 mOhm
L1 = 14 uH
C1 = 13.2 uF
ESR (C1) = 1 mOhm
ESR (L2) = 0 mOhm
L2 = 0 uH
C2 = 240 uF
ESR (C2) = 35 mOhm
R (Normal-Mode) (Load) = 3 Ohm
R (Light-Load-Mode) (Load) = 36 Ohm
Cap Across R1 & R2 = 0 "(1 = Yes: 0 = No)"
Topology = 4 (0 = Full Bridge: 1 = Half Bridge: 2 = Two Switch Forward: 3 = Interleaved Two Switch Forward: 4 = Active Clamp Forward: 5 =
Resonant Mode: 6 = Custom)
Switches / Diodes = 1 (0 = Switches: 1 = Diodes)
High Side / Low Side Sense (CS2) = 0 (1 = High-Side: 0 = Low-Side Sense)
Second LC Stage = 1 (1 = Yes: 0 = No)
CS1 Input Type = 0 (1 = AC: 0 = DC)
R3 = 0 KOhm
R4 = 0 KOhm
PWM Main = 1 (0 = OUTA: 1 = OUTB: 2 = OUTC: 3 = OUTD: 4 = SR1: 5 = SR2: 6 = OUTAUX)
Rev Prelim A Oct.2009 | Page 22 of 27
Reference Design
PRD 1168
REGISTER SETTING
Reg(0h) = F8h - Fault Register 1
Reg(1h) = 0h - Fault Register 2
Reg(2h) = 4h - Fault Register 3
Reg(3h) = 44h - Fault Register 4
Reg(4h) = F8h - Latched Fault Register 1
Reg(5h) = 0h - Latched Fault Register 2
Reg(6h) = 4h - Latched Fault Register 3
Reg(7h) = 45h - Latched Fault Register 4
Reg(8h) = 33h - Fault Configuration Register 1
Reg(9h) = 3Fh - Fault Configuration Register 2
Reg(Ah) = F0h - Fault Configuration Register 3
Reg(Bh) = 0h - Fault Configuration Register 4
Reg(Ch) = 0h - Fault Configuration Register 5
Reg(Dh) = 0h - Fault Configuration Register 6
Reg(Eh) = 81h - Flag Configuration
Reg(Fh) = 66h - Soft-Start Flag Blank
Reg(10h) = 0h - First Flag ID
Reg(11h) = FFh - Reserved
Reg(12h) = 0h - VS1 Value
Reg(13h) = 0h - CS1 Value
Reg(14h) = 0h - CS1 x VS1 Value
Reg(15h) = 0h - VS1 Voltage Value
Reg(16h) = 0h - VS2 Voltage Value
Reg(17h) = 148h - VS3 Voltage Value
Reg(18h) = 0h - CS2 Value
Reg(19h) = 0h - CS2 x VS3 Value
Reg(1Ah) = 4DE0h - RTD Temperature Value
Reg(1Bh) = FFh - Reserved
Reg(1Ch) = FFh - Reserved
Reg(1Dh) = 0h - Share Bus Value
Reg(1Eh) = C0h - Modulation Value
Reg(1Fh) = FFh - Line Impedance Value
Reg(20h) = FFh - Reserved
Reg(21h) = 87h - CS1 Gain Trim
Reg(22h) = 2Ah - CS1 OCP Limit
Reg(23h) = 3Bh - CS2 Gain Trim
Reg(24h) = 10h - CS2 Offset Trim
Rev Prelim A Oct.2009 | Page 23 of 27
Reference Design
PRD 1168
Reg(25h) = 0h - CS2 Digital Trim
Reg(26h) = 3Ah - CS2 OCP Limit
Reg(27h) = 0h - CS1 and CS2 OCP Setting
Reg(28h) = 0h - VS Balance Gain Setting
Reg(29h) = 0h - Share Bus Bandwidth
Reg(2Ah) = 30h - Share Bus Setting
Reg(2Bh) = 1Bh - Temperature Trim
Reg(2Ch) = 62h - PSON/Soft Start Setting
Reg(2Dh) = 0h - Pin Polarity Setting
Reg(2Eh) = 12h - Modulation Limit
Reg(2Fh) = 0h - OTP Threshold
Reg(30h) = C0h - OrFET
Reg(31h) = A4h - VS3 Voltage Setting
Reg(32h) = 0h - VS1 Overvoltage Limit
Reg(33h) = Ah - VS3 Overvoltage Limit
Reg(34h) = 0h - VS1 Undervoltage Limit
Reg(35h) = 0h - Line Impedance Limit
Reg(36h) = 7h - Load Line Impedance
Reg(37h) = FFh - Reserved
Reg(38h) = CAh - VS1 Trim
Reg(39h) = 9h - VS2 Trim
Reg(3Ah) = CFh - VS3 Trim
Reg(3Bh) = 0h - Light Load Disable Setting
Reg(3Ch) = 5h - Silicon Revision ID
Reg(3Dh) = 41h - Manufacturer ID
Reg(3Eh) = 43h - Device ID
Reg(3Fh) = 10h - OUTAUX Switching Frequency Setting
Reg(40h) = 1Fh - PWM Switching Frequency Setting
Reg(41h) = 0h - PWM 1 Positive Edge Timing
Reg(42h) = 20h - PWM 1 Positive Edge Setting
Reg(43h) = 24h - PWM 1 Negative Edge Timing
Reg(44h) = 48h - PWM 1 Negative Edge Setting
Reg(45h) = 2h - PWM 2 Positive Edge Timing
Reg(46h) = 0h - PWM 2 Positive Edge Setting
Reg(47h) = 22h - PWM 2 Negative Edge Timing
Reg(48h) = 48h - PWM 2 Negative Edge Setting
Reg(49h) = 12h - PWM 3 Positive Edge Timing
Reg(4Ah) = 28h - PWM 3 Positive Edge Setting
Reg(4Bh) = 42h - PWM 3 Negative Edge Timing
Rev Prelim A Oct.2009 | Page 24 of 27
Reference Design
PRD 1168
Reg(4Ch) = E0h - PWM 3 Negative Edge Setting
Reg(4Dh) = 0h - PWM 4 Positive Edge Timing
Reg(4Eh) = 0h - PWM 4 Positive Edge Setting
Reg(4Fh) = 11h - PWM 4 Negative Edge Timing
Reg(50h) = 0h - PWM 4 Negative Edge Setting
Reg(51h) = 2h - SR 1 Positive Edge Timing
Reg(52h) = 70h - SR 1 Positive Edge Setting
Reg(53h) = 22h - SR 1 Negative Edge Timing
Reg(54h) = 88h - SR 1 Negative Edge Setting
Reg(55h) = 23h - SR 2 Positive Edge Timing
Reg(56h) = A8h - SR 2 Positive Edge Setting
Reg(57h) = 1h - SR 2 Negative Edge Timing
Reg(58h) = 20h - SR 2 Negative Edge Setting
Reg(59h) = 0h - PWM AUX Positive Edge Timing
Reg(5Ah) = 0h - PWM AUX Positive Edge Setting
Reg(5Bh) = 3Ah - PWM AUX Negative Edge Timing
Reg(5Ch) = F0h - PWM AUX Negative Edge Setting
Reg(5Dh) = 98h - PWM and SR Pin Disable Setting
Reg(5Eh) = 0h - Password Lock
Reg(5Fh) = 0h - Soft-Start Digital Filter LF Gain Setting
Reg(60h) = 7h - Normal Mode Digital Filter LF Gain Setting
Reg(61h) = F8h - Normal Mode Digital Filter Zero Setting
Reg(62h) = F7h - Normal Mode Digital Filter Pole Setting
Reg(63h) = 11h - Normal Mode Digital Filter HF Gain Setting
Reg(64h) = Eh - Light Load Digital Filter LF Gain Setting
Reg(65h) = D6h - Light Load Digital Filter Zero Setting
Reg(66h) = D5h - Light Load Digital Filter Pole Setting
Reg(67h) = 12h - Light Load Digital Filter HF Gain Setting
Reg(68h) = 0h - Dead Time Threshold
Reg(69h) = 0h - Dead Time 1
Reg(6Ah) = 0h - Dead Time 2
Reg(6Bh) = 0h - Dead Time 3
Reg(6Ch) = 0h - Dead Time 4
Reg(6Dh) = 0h - Dead Time 5
Reg(6Eh) = 0h - Dead Time 6
Reg(6Fh) = 0h - Dead Time 7
Reg(70h) = 14h Reg(71h) = Bh Reg(72h) = 53h Rev Prelim A Oct.2009 | Page 25 of 27
Reference Design
PRD 1168
Reg(73h) = 9h Reg(74h) = 0h Reg(75h) = FFh Reg(76h) = FFh Reg(77h) = 0h Reg(78h) = 0h Reg(79h) = 1Bh Reg(7Ah) = 2h Reg(7Bh) = FFh - Factory Default Settings
Reg(7Ch) = 1h - EEPROM X Address
Reg(7Dh) = 35h - EEPROM Y Address
Reg(7Eh) = 35h - EEPROM Register
Reg(7Fh) = FFh Reg(80h) = 35h Reg(81h) = 35h Reg(82h) = 35h -
Rev Prelim A Oct.2009 | Page 26 of 27
Reference Design
PRD 1168
NOTES
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Rev Prelim A Oct.2009 | Page 27 of 27